P63.50-2159-06
| Removing | ||
Danger! | Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | |
Danger! | Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. | |
Danger! | Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
| Measures for preventing damage to vehicles or components when performing electric welding work | ||
| General information on repairs to body | ||
| Guidelines for removing fuel tank when performing welding work on bodies | ||
| Notes on paintwork repairs | ||
| General information on MB materials | ||
1 | Prepare required workshop equipment and commercially available tools for repair | ||
2 | Remove trunk lid | ||
3 | Remove rear wall window | ||
4 | Remove all detachable body components in area to be repaired. | ||
5 | Cover all detachable parts remaining vehicle with fireproof tarpaulin | ||
6 | Install filler neck covering | When replacing right rear fender. | |
Latches | |||
7 | Separate rear fender | ||
Spot weld cutter | |||
Cutting templates | |||
Round wire brush gotis://K_58.3_06.0 | |||
Weld-spot milling machine gotis://K_58.1_02.0 | |||
Beading pliers gotis://K_58.3_04.1 | |||
Hot-air gun gotis://K_60-65_11.0 | |||
Hand drill (with chuck up to 16 mm dia.) gotis://G_58.0_00.1 | |||
Angle grinder up to 125 mm gotis://G_58.0_06.0 | |||
Keyhole saw gotis://K_58.1_01.0 | |||
Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |||
Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) | |||
Zinc dust paint suitable for spot welding | |||
8 | Prepare new rear fender part | ||
Cutting templates | |||
Punching pliers gotis://K_58.3_04.0 | |||
Round wire brush gotis://K_58.3_06.0 | |||
Hand drill (with chuck up to 16 mm dia.) gotis://G_58.0_00.1 | |||
Keyhole saw gotis://K_58.1_01.0 | |||
Sealant | |||
Zinc dust paint suitable for spot welding | |||
| Install | ||
9 | Install rear fender, fit and weld in | ||
| General information on riveting | ||
Bending iron | |||
Feeler gauge | |||
Round wire brush gotis://K_58.3_06.0 | |||
Vice grip pliers (standard) gotis://K_58.3_04.2 | |||
Vice grip pliers (special, small) gotis://K_58.3_04.3 | |||
Hand riveting tool (for blind pop rivets) gotis://K_68-80_06.0 | |||
Inert gas welder gotis://K_60-65_17.0 | |||
Multifunction device (spot welding) gotis://K_60-65_15.0 | |||
Hand drill (with chuck up to 16 mm dia.) gotis://G_58.0_00.1 | |||
Angle grinder up to 125 mm gotis://G_58.0_06.0 | |||
Wet and dry vacuum cleaner gotis://P_00.12_06.0 | |||
Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm) | |||
Front door to roof | |||
Rear door to side section, bottom | |||
Trunk lid to rear fender, top | |||
Trunk lid to rear lamp unit | |||
Fuel filler flap | |||
Sealant | |||
Preservation agent | |||
Zinc dust paint suitable for spot welding | |||
Rivet | |||
10 | Adjust gap dimensions on hoods, doors and lids | Model 203.004/006/007/008/016/018/020/ 035/040/042/043/045/046/052/054/056/ 061/064065/081//084/087/092 | |
Type 203.076 | |||
Feeler gauge | |||
Front door to roof | |||
Rear door to side section, bottom | |||
Trunk lid to rear fender, top | |||
Trunk lid to rear lamp unit | |||
Fuel filler flap | |||
11 | Shape body flange for taillamp with embossing tool | ||
Embossing tool | |||
12 | Clean weld joints and sheet metal flange with round wire brush | ||
13 | Clean repair areas | ||
14 | Prime area to be repaired using primer filler | ||
15 | Carry out seam sealing after repairs | Supplement standard sealant with sealant. | |
Sealant | |||
Seam sealant, sprayable 310 ml | |||
16 | Paint repair areas and adjacent surfaces | ||
17 | Apply additional cavity preservation | ||
| Notes on cavity preservation | ||
Preservation agent | |||
18 | Remove covers for filler neck | When replacing right rear fender. | |
19 | Remove tarp | On all covered parts remaining in vehicle. | |
20 | Install rear wall window | ||
21 | Install trunk lid | ||
22 | Install all detachable body components in area to be repaired. |
Test values for gap dimensions on hoods, doors and lids
Number | Designation | Model | Type | |||
BE60.00-P-1002-01E | Gap dimension | Front door to A-pillar | Dimension "B" | mm | 6.5 (+1) | 6.5 (+1) |
Front door to fender | Dimension "H" | mm | 3.5 (–0.5/+1) | 3.5 (–0.5/+1) | ||
Front door to rear door | Dimension "I" | mm | 4 (–0.5/+1) | 4 (–0.5/+1) | ||
Front door to roof | Dimension "C" | mm | 6.5 (+1) | 6.5 (+1) | ||
Rear door to C-pillar | Dimension "T" | mm | - | - | ||
Rear door to side section, bottom | Dimension "J" | mm | 3,5 (+1) | 3,5 (+1) | ||
Front door to rear fender | Dimension "P" | mm | - | - | ||
See picture | – | |||||
BE60.00-P-1003-01E | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | 3.5 (1) | 3.5 (1) |
Trunk lid to rear lamp unit | Dimension "M" | mm | 4 (1) | 4 (1) | ||
Rear fender to rear lamp unit | Dimension "U" | mm | - | - | ||
See picture | – | |||||
BE60.00-P-1005-01E | Gap dimension | Fuel filler flap | Dimension "K" | mm | 3.5 (0.5) | 3.5 (0.5) |
See picture | – | |||||
203 589 06 23 00
Latches
Cutting templates
Spot weld milling cutter
Bending iron
201 589 00 51 00
203 589 00 91 00
129 589 00 27 00
164 589 00 39 00
Embossing tool
Feeler gauge
129 589 03 21 00
Repair materials
Number | Designation | Order number |
BR00.45-Z-1003-01A | Sealant, white, 310 ml, DB supply specification 6069.20 | A 001 989 63 20 |
BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
BR00.45-Z-1003-05A | Cavity preservation, solvent-free (1 l container) | A 000 986 72 70 05 |
BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
BR00.45-Z-1001-13A | Blind rivet 6.414 | A 003 990 35 97 |
Referenced documents
- ah0000n000501a Measures for preventing damage to vehicles or components when performing electric welding work
- ah6000n000101a General information on body repair
- ah6000p000301n General information on riveting
- ah6000p300001z Guidelines for removing fuel tank when performing welding work on bodies
- ah9720p000101b Notes on cavity preservation
- ah9800p940802a Notes on paintwork repairs
- ah9800p940903a General information on MB materials
- ar6000p070001ac Gap dimensions on hoods, doors and lids
- ar6000p070001p Gap dimensions on hoods, doors and lids
- ar6350p140001p Remove/install cover for filler fitting
- ar6350p140002p Separate rear fender
- ar6350p140003p Preparing new rear fender
- ar6350p140004p Install rear fender
- ar6350p140009cw Shape body flange for taillamp with embossing tool
- ar6720p2000p Remove/install rear wall window
- ar8850p5000p Remove/install trunk lid
- ar9710p4000p Seam sealing following repair
- ar9720p1500p Cavity preservation following repair work
- as0000z000701a The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from
- as0000z001701a Risk of injury caused by scraping or cutting body parts on sharp vehicle parts
- as4700z000101a Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.